Prefabricated sealed building construction



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PREFABRICATED SEALED BUILDING CONSTRUCTION Filed June '7. 1955 '7 Sheets-Sheet 7 ,IIIIIIII irralem'x i kill United States Patent PREFA'BRICATED SEALED BUILDING CONSTRUCTION George F. Hauf, River Forest, 111., assignor to Chicago Metal Mfg. 'Co., Chicago, Ill., a corporation of Illinois Application June 7, 1955, Serial No. 513,674

5 Claims. (Cl. 20-2) My invention rel-ates to improvements in prefabricated building construction.

My invention relates more particularly to the construction of scaled buildings which may be assembled and builtwhere desired from certain standard prefabricated sections, panels and joints which form the walls of a room or building with the necessary insulating qualities.

Prefabricated panels and joints have been used in the past for the construction of ovens and other buildings for the baking of finishes, products or chemicals, or in low temperature heat treating where heat insulating structure is required, and also to structures utilized in the smoking and treatment of hams, bacon, sausages and the like where a structure must have tightly sealed joints. One such structure is shown in a previously issued United States Patent No. 2,300,743 to George F. Hauf and James J. Egan.

In recent years there has been a demand for totally enclosed rooms, especially designed, constructed and mounted to eliminate external noise and vibration. Specifically, such rooms are used for audiometric testing of the hearing qualities of persons and are placed in factories, shops and doctors ofiices for this purpose. Since various buildings or ofiices in which they are placed are of various sizes with different locations or doors and windows, the totally enclosed and sealed room structure must be such that panels, doors and windows of the same are inter-changeable and may be assembled to suit the particular location selected for its site. Also, in any assembly the wall joints, including floor and ceiling and the window and door openings, must have a sealing quality which will exclude and prevent entrance of sound, air, water or other fluid.

With these and other purposes in mind, the principal object of the invention is to provide a room structure made up of prefabricated panels and parts adapted to be assembled at the place of use, which structure is easily assembled in such a way that the joints between aligned wall panels and the joints between the wall and floor and ceiling or roof panels are hermetically and structurally tight and have the highest of insulating qualities.

Another object of the invention is to so construct the prefabricated wall panels, joints, doors and windows in such manner that in a disassembled condition all of the parts are flat and can be easily packaged, handled and shipped.

Another object of the invention is to provide a room structure comprising wall, roof and floor panels adapted to be joined together, and joint structures for such purpose that not only provide hermetically tight joints, but also provide strong walls which are structurally rigid and will withstand exceptionally hard and continuous usage.

A further object of the invention is to provide joint structures for the wall panels, roof, floor and the door frame and door which present a neat and attractive appearance when assembled.

A further object of the invention is to provide a standard door frame and door capable of assembly with the roof and floor of the building at any side or location in a side wall, the door frame being capable of attachment to the standard wall panels and also fitting into the floor and roof to present an unbroken appearance of the same.

A further object of the invention is to provide an improved construction of door and door frame which is effective upon closing the door to hermetically seal the entire periphery of the door opening, yet the means for opening and closing the door either from within or with* out will be sufficiently easy to operate so that children and weak and ill persons can easily manipulate the door opening and closing means.

Other objects and advantages will be more apparent from the following description wherein reference is had to the accompanying drawings, upon which Fig. 1 is a front perspective view of a room embodying a preferred form of the invention;

Fig. 2 is a diagrammatic plan section view of the room taken on the line 22 of Fig. 1;

Fig. 3 is a transverse sectional view taken on the line 33 of Fig.- 1 through the roof panel and a portion of the upper ends of the side wall panels, the view being foreshortened to show the details of construction on a larger scale and the view showing alternate forms of roof construction;

Fig. 4 is a similar transverse sectional view through the floor panel and portions of the side wall panels of the building showing the manner in which the side wall panels are attached to the floor panel, the view being foreshortened to show the details in a larger size;

Fig. 5 is a fragmentary plan sectional view through a pair of the side wall panels and the connector member which fastens the same together, the view being taken on the line 55 of Fig. l

Fig. 6 is a fragmentary perspective view of one of the channel fastener members shown in Fig. 5;

Fig. 7 is a similar perspective view of the other channel fastener member that is shown in Fig. 5;

Fig. 8 is a plan sectional view of one of the corner wall panels taken on the line 88 of Fig. 1;

Fig. 9 is a side elevational view thereof, the view being foreshortened and parts being broken away to more clearly show other parts; I

Fig. 10 is a plan sectional view through the door, door frame and associated side wall panels, the view being taken generally on the line 10-10 of Fig. 1;

Fig. 11 is a front elevational View of the door frame; and

Fig. 12 is a vertical sectional view through the door, door frame, floor and roof panels, and is taken generally on the line 1212 of Fig. 1.

In the embodiment of the invention which I have chosen to illustrate and describe the same, I show a room 10 which may generally consist of a rectangularly shaped roof section 12, a floor panel 14, four side corner wall panels 16, intermediate wall panels 13, a door frame 22, and a door 20. One or more suitable windows 24 may be built into one or more of the side wall panels 18 if desired. v

As best shown in Fig. 3, the roof panel 12 may be formed with two metal rectangularly shaped pans, an inverted cover pan 12a which is rectangular in shape and of the desired size of the building, the pan having a downwardly depending peripheral flange 12b extending about the entire periphery of the same. An inner pan 12a is provided having a peripheral transverse flange 12d and a laterally extending flange He, the flange 12e adapted to be fastened to the bottom wall of the roof portion of pan 1211 by welding or otherwise to provide a channel about two inches wide around the entire periphery of the roof panel. Positioned within the inner pan is a sound deadening unit 26 comprising a wooden rectangular frame 28, a pair of sheets of tar paper 30 fastened to the frame 28 by wooden fastening strips 32 about the edges of the same. The strips 32, paper 39 and frame 28 are fastened together by nails or other suitable fasteners and form a rectangular frame which fits in the pan 12c and forms an effective sound deadening and insulating unit. In addition, the inside surface of the walls of the pans 312a and 120 may be sprayed with a liquid sound deadener to provide a more effective sound deadening construction.

I also provide a layer of rock wool 34 or similar material in a shallow pan 36 which has a peripheral transverse flange 38 and a lateral flange 4-9 extending outwardly therefrom to fit within the edge flange 12b of the roof. Suitable filler blocks 42 are placed around the four sides of the channel.

The wall panels 18 which fit into the roof panel in the channel between the flange 12b and the transverse flange 38 may be formed with outer and inner metal wall portions 44 and 46 which have upper and lower inturned edges 4-8 and 50 which extend inwardly toward each other and then have a short transverse bend 52 and a parallel flange 54, the edges of the flanges 54 being welded together to form in effect a rectangularly shaped sheet metal housing. A sound deadening unit is placed in each panel, the unit consisting of a wooden frame 56, a pair of sheets of tar paper 53, and a pair of spacer strips 6%, one on each side of the tar paper. This sound deadening unit is fastened together by nails or other suitable means and placed between the two sheets 44 and .6 before the edges of the flanges 54 are welded together. A channel member 62 is welded between the transverse bends 52 in the end flanges 43 and 549 of the sheet metal members 4- and 46.

The wall panels may be fastened to the roof panel by means of bolt members 64 which extend through the roof panel 12, filler block 4-2 and through suitable openings in the channel 62 and wooden frame 56 to receive a nut 66 that is held in a nut retainer member 68 fastened to the wooden frame 56. A strip of compressible material such as rubber S that is glued or otherwise secured on the peripheral flange 4t} receives the upturned edges of the channel member 62, and as the bolt 64- is drawn up, a tight sound and fluid insulating joint is formed between the top of the wall panels and the roof panel 12. The bolts 64 are preferably spaced at approximately six-inch intervals about the edge of the roof section so that at all points throughout the periphery of the meeting edges a sealed joint is obtained.

The floor panel 14 of the room may be generally simi lar to the roof panel, the same including a rectangularly shaped pan 14a having the peripheral upwardly turned flange 14b. The floor panel may also include a sheet metal inner pan 140 which has a downwardly turned peripheral flange 14:! that terminates in a laterally extending peripheral edge 14a The size of the edge Me is such that it fits closely within the upturned ledge 14b of the floor. The space between the pans 14a and 14c is occupied by a sound deadening unit 26 similar to the unit 26 which is provided in the roof panel. A plywood or other suitable flooring material '70 may be laid upon the top of the pan 140 to provide a flooring in the room.

The side wall panels 18, which are constructed at their lower ends in the same manner as at their upper ends, including the channel 62a, may rest upon a strip of rubber S fastened around the peripheral edge of the pan 14c, the lower ends of the wall panels being secured to the side flanges 14b of the floor panel by wood screw members 72 which are preferably spaced at approximately six-inch intervals. The wall panels 13 may be fastened together along their vertical edges or to the vertical edges of the corner panels 16, as best shown in Figs. 5, 6 and 7.

As previously stated, the side wall panels are constructed of two sheet metal sections 44 and 46 which have their edges inwardly turned as shown at 43 and G, with a short transverse bend and the extensions S-t which are welded together. The two sheet metal sections enclose the sound deadening unit 26 which has previously been described. At the upper and lower ends of the side wall panels the channels 62 and 62a are welded in position and have their edges embedded in the strips of rubber in the roof and floor panels of the room. At the side edges of each wall panel I provide a pair of facing strips 76 which have a portion 73 that is welded to the sheet metal shell of the wall panels. The strips also have transversely extending shoulders 8t} and laterally extending flanges 82 spaced from the edges of the panels 18,

In order to fasten a pair of wall panels together in alignment, I provide a pair of inner and outer channel fastener members 86 and 88 (see Fig. 5). These memhers may be in the form of a channel having the legs W which fit in the space between the edges of the panels 18 and the flanges 82. The inner channel 86 is provided at spaced intervals with nut holding housings 92 which are preferably formed from a single piece of sheet metal having side portions 94 and 96 angularly disposed with respect to the center portion 93 thereof. Flanges 10% extend laterally from the sides so that they can be spot- Welded to the wall of the channel fastener member, retaining a square nut N2 in position therein between the side portions )4 and 96 and end portions 99. The nut holding housings 92 are preferably spaced at approximately six-inch intervals throughout the height of the channel member 86.

The channel member 88 is provided throughout its length with bolt head receiving openings T04 aligned with the nut housing 92, and in assembly receives a bolt 165 through each of the openings 164 which when tightened draws the channel members tightly against the shoulders 81) of the strips 76, thus effecting a fluid-tight seal throughout the entire height of each of the wall panels.

As best shown in Figs. 8 and 9, the corner panels 16 may be generally similar to the wall panels 18, the corner panels, however, being formed with two sound deadening units and 26a, the unit 2651 being provided in the rightangle extension 16a of the corner wall panel. Fastening strips 76 are provided at the side edges of the corner panel for connection to aligned wall panels 18.

in the construction of a building of the type described for use as an audiometric testing room, the dimensions are such that two corner panels 16, a door frame 22 and a door 20 are all that are required at one end of the room. The door frame which I employ, see Figs. 10 to 12, is a rectangular sheet metal member which has a front peripheral flange 22a, a side wall 221), an inwardly turned back peripheral flange 22c which has an inturned ledge 22d parallel to the wall 22b. The combination of the wall 22/), flange 22c and ledge 22d form a pocket for a generally square peripheral rubber pad or strip R that surrounds the opening 22e of the door frame.

The door frame 22 may be fastened along its side edges through the front flange 22a to the edge of the corner panel 16 by means of wood screws 196 which extend through openings M8 at six-inch intervals throughout the height of the door frame. A strip of rubber or other insulator may be positioned between the flange 22a and the sides of the edge panels 16. The upper edge of the door frame 22 may be fastened by screw members 196 in like manner to the sound deadener section 26 in the roof panel 12. A filler block 111 is provided between the rubber sealing member S to fill in the space between the flange it) of the insulator unit 3 5. and the flange 22b of the door frame. Similarly, the lower edge of the door frame is fastened by screw members 106 to a filler block 112 that has been placed in the front channel of the floor between the vertical side edges of the corner units 16.

By means of a suitable hinge 116 along one edge of the same, the door which I employ may be connected to one of the vertical walls of the door frame. The door 20 which is rectangular in shape and of a size slightly smaller than the opening in the door frame, may be constructed t ate heet metalnen 94. whTg ha the i tu p r phal e e 2. thatte m a e i a r n v s flange 206 that is then bent inwardly again to form the edge 20d. A pan 20e-has a1i-inturned :flange 20 which fits over the edge 20d, the flange, 20f;terminating in an outwardly turned peripheral flange 20g which fits against the wall 20g of the member 20a and is spot-welded thereto throughout its periphery. The hollow door, unit thus formed encloses a sound deadening unit 26' of the type previously described. v H

- An angle-shaped strip 128 is welded or otherwise suitably fastenedon-the surface of theflange 20g around the entire periphery of the door, thestrip having an outwardly" directed'lip-portion 'which, when the door is closed, embeds itself about theperiphery of the door in the rubber strip R, thus providing an effective sound and fluid proof seal about the entire door in the door frame. A suitable latch 130 of any desirable type may be provided for opening and closing the door in the door frame.

From the above and foregoing description it can be seen that I have provided a prefabricated building or room structure, the roof, floor, wall panels, door frame and door all capable of being packed for shipment in a relatively flat condition and in easily handled packages. Further, the packages can be assembled at the factory in accordance with the size of the room that has been ordered, and the door frame and door may be placed in any suitable or desirable side of the room depending upon the surroundings of the building in which it is to be located. The assembly is comparatively simple in that in assembling the building at its location the floor panel can be laid down, the wall and corner panels assembled together along with the door frame and door, and the final step will be the placing of the roof panel on top of the upper ends of the wall and corner panels and fastening the same in position by means of the bolts, as described.

While I have illustrated and described a specific embodiment of the invention, it will be apparent to those skilled in the art that changes and modifications may be made in the exact details shown and I do not wish to be limited in any particular; rather what I desire to secure and protect by Letters Patent of the United States is:

1. A sealed building constructed on location of prefabricated units, one of said units being a flat rectangular roof panel having a downwardly turned U-shaped trough about its periphery, the outer edge of the same being a downwardly turned flange, a similar rectangular floor panel having an upwardly facing U-shaped trough, the outer edge of its trough being an upwardly turned flange, a flat filler block in each roof trough throughout its entire length, rectangular wall panels having their upper ends engaged in said troughs and fastened through said filler blocks to said roof panels, a rubber pad in each floor trough, the lower end of each side panel resting on the same to form a hermetic seal between the lower ends of the wall panels and the trough of said floor panel, structural fastening and hermetic sealing means between adjacent vertical edges of each of said wall panels, said means including vertical fastening strips attached to but spaced from the facing edges of said wall panels, and vertical facing channel members each having a leg overlying an edge of the fastening strip of adjacent wall panels, said channels bolted together to form a flush wall line with adjacent panels.

2. A sealed building constructed on location of prefabricated units, one of said units being a rectangular roof panel having a downwardly facing U-shaped trough about its periphery, the outer edge of the same being a downwardly turned flange, a similar rectangular floor panel having an upwardly turned U-shaped trough, the outer edge of its trough being an upwardly turned flange, a flat filler block in each roof trough throughout its length, vertical rectangular wall panels having their top and bottom ends engaged in said troughs, spaced bolts extending through said roof an its filler block into said wall panels to fasten the top of said wall panels thereto, a rubber pad ineach floor trough, the lower end of each side panel resting on the same to form a hermetic seal between the lower ends of the wall panels and the trough of said floor panel, structural fastening and hermetic sealing'means between adjacent edges of each of said wall panels, a doorframe interposed between two adjacent wall panels, said door frame being a rectangularly shaped panel having an outwardly directed edge flange overlying a portion of the wall panel on each side of it and a portion of the opposed vertical flanges of the roof and floor panels and being fastened thereto, a rubber strip around said door between its peripheral edge flanges and the vertical edges of said wall panels and between said edge flanges and the op posed flanges of said door and roof troughs, said door frame having an inwardly directed peripheral flange forming a narrow peripheral trough, a strip of rubber therein and a door hingedly connected on one side of said door frame and having a peripheral inwardly directed lip portion which embeds itself in said rubber strip when the door is closed.

3. A sealed building structure comprising a rectangular floor panel, a rectangular roof panel, rectangularly shaped vertical wall panels and corner panels, joints for hermetically and structurally connecting said wall panels and corner panels together to form a rectangular enclosure of desired width and length, and means for hermetically and structurally connecting the lower ends of said wall and corner panels to said floor panel and for hermetically and structurally connecting the upper ends of the wall and corner panels to said roof panel, said upper and lower ends of said wall and corner panels having shallow outwardly facing U-channels, the upper edge of the floor panel and the under side of said roof panel each having a peripheral U-shaped trough into which the upper and lower ends of said wall panels and corner panels fit, a filler block in said roof trough engaging the shallow U-channel at the upper ends of said wall and corner panels and spaced bolts extending through said roof panels and said filler blocks into the upper edges of said wall and corner panels to fasten said structure together.

4. A sealed building structure comprising a floor panel, a roof panel, vertical wall panels and corner panels, joints for hermetically and structurally connecting the side edges of said wall panels and corner panels together to form an enclosure of desired width and length, said joints including vertical strips having outwardly directed vertical ledges spaced from and parallel to v the side edges of said wall and edge panels, facing U-shaped vertically disposed channels bolted together with facing legs fastened over juxtapositioned legs on two aligned side panels, means for hermetically and structurally connecting the lower ends of said wall and corner panels to said floor panel and means for hermetically and structurally connecting the upper ends of the wall and corner panels to said roof panel, said lower and upper ends of said wall and corner panels having outwardly facing shallow U-channels, said roof and floorpanels each having a peripheral U-shaped trough, a strip of rubber on the floor of each trough of said roof and floor panels, the upper and lower ends of said wall and corner panels received in said troughs and bolts at spaced intervals connecting said roof to the upper ends of said wall and corner panels.

S. In a sealed building construction formed of prefabricated panels, the combination comprising a rectangular roof panel having a downwardly directed peripheral channel forming an edge trough, a similar rectangular floor panel having an upwardly directly peripheral channel forming a trough, elongated rectangular wall panels set up in alignment in said floor panel trough, rectangularly shaped corner panels set up in each corner in alignment with said Wall panels, all of said wall and corner panels having outwardly turned vertical spaced flanges on their vertical edges throughout their length, facing vertical U-channels embracing said flanges throughout their length, said U-channels fastened together to hermetically and structurally connect the wall and corner panels in edge to edge relation and the upper and lower ends of all of said wall and corner panels seated in the downwardly directly trough of said roof 10 panel and in the upwardly directed trough of said floor panel and being fastened thereto, each of said peripheral troughs having a layer of sealing material in the base of the same, and shallow U-shaped channel members across the upper and lower edges of said wall panels and 15 2,651,391

corner panels, their legs being embedded in said sealing material whereby both a hermetic and mechanical connection is made to said roof panel and said floor panel.

References Cited in the file of this patent UNITED STATES PATENTS 1,730,464 Levine Oct. 8, 1929 1,908,661 Foltz May 9, 1933 2,060,608 Butler et a1 Nov. 10, 1935 2,300,743 Hauf et al. Nov. 3, 1942 2,351,209 Hobbs June 13, 1944 2,394,594 Cohn Feb. 12, 1946 2,585,082 Bollinger Feb. 12, 1952 2,589,633 Shepheard Mar. 18, 1952 Havens Sept. 8, 1953 

